IDAC were required by AB Electronic to carry out an FE analysis on a new design of a clip to be used in the automotive industry. The reliability of the new design and the flexibility of the components within the clip assembly were to be determined. In order to check the reliability of the clip the assembly load had to be established. An assembly load in the region of 50N was required for optimum usability.
The 3D geometry was provided by AB Electronic in Autodesk Inventor format. The model was imported into ANSYS Workbench and meshed using 3D tetrahedral elements. The graphics above show both the geometric model and the meshed model. Plastic material properties were defined in ANSYS for the clip. Fully bonded contact elements were generated between all parts in contact, automatically, within ANSYS Workbench. Areas which were then able to separate were selected and the contact status was modified to frictional contact.
Results showed that the assembly load was in the region of 43N. This satisfied the design criteria.The graph to the right shows the change in the assembly load of the clip.
The graphics to the above left shows an equivalent stress contour plot of the top part of the clip. The area of high stress is in the bend region of the top part of the clip was as expected and was found to be within an acceptable range.